Cybernetworks Provides Hardware Solutions for Large-Format PCB Manufacturing & Assembly

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Cybernetworks is a trusted provider of PCB prototyping, industrial circuit board repair, and complete PCB manufacturing and assembly solutions. With the capability to accommodate exceptionally large and heavy boards—up to 20" x 25" in size, 0.250" in thickness, and weighing as much as 15 lbs—Cybernetworks stands out as a specialized partner for demanding and non-standard PCB requirements. Be it rapid prototyping, high-precision assembly, or robust repair services, Cybernetworks delivers reliable results across a wide range of circuit board applications.

Cybernetworks brings deep industry expertise in large-format printed circuit board (PCB) manufacturing and assembly, with a particular focus on Automatic Test Equipment (ATE) and Burn-In Board (BIB) hardware. These systems are critical to semiconductor testing environments and demand extremely precise fabrication tolerances, reliable materials, and assembly expertise—requirements that Cybernetworks has consistently met for its clients.

ATE hardware often involves some of the most challenging PCB requirements in the industry. Systems such as Spea C600MX, C600MX-C, and Teradyne J750 feature oversized load boards that can measure up to 20” x 25”, reach thicknesses of 0.250”, and consist of as many as 40 layers. These boards can weigh up to 9 pounds before even being assembled, well beyond the handling capabilities of typical pick-and-place machines.

Cybernetworks is uniquely positioned to deliver complete, double-sided hardware solutions for these systems, including Probe Cards, Load Boards, and DUT (Device Under Test) PCBs. By combining specialized assembly capabilities with experience across various ATE platforms, the company serves as a one-stop partner for mission-critical test board builds, at significant cost savings compared to original ATE vendors and large-scale contract manufacturers.

Unlike high-volume contract manufacturers with rigid assembly lines, Cybernetworks operates with the flexibility of a small business. This agility enables rapid line changes and fast turnarounds, with some complete fab-and-assembly projects delivered in as little as five business days, depending on complexity. This efficiency—combined with lean operations—allows the company to offer competitive pricing while maintaining high quality standards.

All ATE and burn-in PCB fabrication is performed exclusively by top-tier PCB manufacturers located in the United States. Cybernetworks maintains close partnerships with these vendors to ensure compliance with strict flatness, thickness, and material specifications essential for high-performance testing hardware. Once fabricated, the PCBs are shipped overnight to the company’s Phoenix, Arizona, facility for final surface mount technology (SMT) and through-hole assembly, ensuring fast project completion and strict quality control.

Burn-In Boards (BIBs) present their own unique set of challenges. These boards must endure prolonged high-temperature cycles during testing, which necessitates careful material and process selection. Cybernetworks addresses these challenges by exclusively using lead-free SAC305 solder for all burn-in assemblies, eliminating the reliability risks associated with improper solder choices seen in some competitor products.

In addition, polyimide materials—preferred for their thermal resilience over standard FR4—are standard in Cybernetworks' BIB manufacturing process. However, polyimide’s tendency to absorb moisture requires careful pre-treatment to prevent delamination during SMT reflow. Cybernetworks mitigates this with its in-house Blue M bake oven, capable of pre-baking boards up to 19.95" x 24.95", thus preserving the integrity of even the largest burn-in boards.

With years of specialized experience and a customer-first approach, Cybernetworks is the go-to partner for companies seeking reliable, cost-effective, and fast PCB manufacturing and assembly for ATE and burn-in systems.

Click here to learn more about Large PCB Board Manufacturing and PCB Assembly capabilities of Cybernetworks.